FIELD OF THE INVENTION
[0001] The present embodiments generally relate to articles of footwear, and more particularly
relate to articles of footwear having a sole structure incorporating a lobed fluid-filled
chamber.
BACKGROUND
[0002] Articles of footwear generally include an upper and a sole structure.
[0003] An upper generally forms a footwear body that extends over a portion of a foot to
retain the article of footwear on the foot. An upper may extend over an instep and
toe areas of the foot, along medial and lateral sides of the foot, and/or around a
heel area of the foot. An upper may be formed from one or more material elements,
such as textiles, polymer sheet layers, foam layers, leather, synthetic leather, and
other materials. These materials may be attached together, such as by stitching or
adhesive bonding. An upper may be configured to form an interior of the footwear that
comfortably and securely receives a foot. An upper may include an opening that facilitates
entry and removal of the foot from the interior of the upper and further may include
a closure system, such as lacing, cinches, or straps that enables a wearer to adjust
a fit of the article of footwear.
[0004] A sole structure generally is attached to the upper and disposed between the foot
and a ground surface. For example, a sole structure may be attached to a lower portion
of the upper. A sole structure may include one or more components, including one or
more of the following: an outsole, a midsole, an insole, an insert, a bladder or a
fluid-filled chamber, such as an airbag. A sole structure also may include other components
or elements, such as ground surface traction elements.
[0005] An upper and sole structure may operate to provide a comfortable article of footwear
structure configured to benefit a wearer engaged in any of a variety of activities.
For example, a sole structure may operate to attenuate impact and ground reaction
forces and/or to provide traction on a ground surface. An upper and sole structure
may cooperate to control various foot motions, such as pronation.
[0006] US 2009/0090025 discloses an article of footwear that includes an upper and a sole structure which
includes a midsole and an outsole. The footwear also includes at least one lobe between
the upper and the outsole that extends laterally beyond a heel area of the upper and
meets the sole at the lobe's edge that is laterally farthest away from the upper so
that the lobe is exposed such that when viewed from above, in a direction perpendicular
to the sole, the lobe is at least partially visible beyond the sides of the heel.
SUMMARY
[0007] An article of footwear according to appended independent claim 1 is provided, the
article having a sole structure including a lobed fluid-filled chamber component and
inter-fitted midsole component, such as a polymer foam material component, provides
improved customization, cushioning, and flexibility performance characteristics of
the sole structure and article of footwear.
[0008] In one aspect, an element of a sole structure for an article of footwear includes
a fluid-filled chamber component having a central portion, a plurality of lobes extending
outward from the central portion, and a plurality of channels formed between the plurality
of lobes, the plurality of channels extending in a direction from a top surface of
the fluid-filled chamber component to a bottom surface of the fluid-filled chamber
component, at least a first channel of the plurality of channels defined by two adjacent
lobes of the plurality of lobes forming a side opening of the first channel located
opposite the central portion of the fluid-filled chamber component, the side opening
of the first channel corresponding to a portion of a peripheral side of the sole structure,
and at least a first lobe of the two adjacent lobes forming the side opening of the
first channel having an exposed distal end wall that forms a portion of a peripheral
side surface of the sole structure, the exposed distal end wall having a projecting
portion that extends further outward from the central portion than the portion of
the peripheral side of the sole structure associated with the exposed open side of
the first channel.
[0009] In another aspect, a sole structure for an article of footwear includes a fluid-filled
chamber component having a central portion, a plurality of lobes extending outward
from the central portion, and a plurality of channels formed between the plurality
of lobes, the plurality of channels extending in a direction from a top surface of
the fluid-filled chamber component to a bottom surface of the fluid-filled chamber
component, and a midsole component inter-fitted with the plurality of lobes of the
fluid-filled chamber component, a plurality of projections of the midsole component
extending through the plurality of channels of the fluid-filled chamber component,
the midsole component forming a portion of a peripheral side surface of the sole structure,
wherein at least a first lobe of the plurality of lobes has an exposed distal end
wall including a projecting portion that extends further outward from the central
portion of the fluid-filled chamber component than the portion of the peripheral side
surface of the sole structure formed by the midsole component.
[0010] In some embodiments, at least one of the plurality of lobes may have a trapezoidal
or triangular cross section. In some embodiments, at least one of the plurality of
channels may have a generally truncated conical configuration and/or a generally trapezoidal
or triangular cross section. In some embodiments, the projecting portion may be formed
by a surface portion of an exposed distal end wall that is arranged at an angle. In
some embodiments the projecting portion may be formed by an edge portion of a faceted
surface of the exposed distal end wall. In some embodiments the projecting portion
may be a generally trapezoidal edge portion.
[0011] In some embodiments, the midsole component may have an upper surface, a lower surface,
and a plurality of projections that extend through and are inter-fitted with the plurality
of channels of the fluid-filled chamber component in a direction from the top surface
of the fluid-filled chamber component to a bottom surface of the fluid-filled chamber
component, and wherein exposed side walls of the plurality of projections form the
portion of the peripheral side surface of the sole structure. In some embodiments,
the midsole component may include a flex structure, such as a triangular or trapezoidal
wedge-shaped indentation on an exposed side wall of at least one of the plurality
of projections. In some embodiments, the midsole component may include a flex structure,
such as a lateral groove formed at a distal end of at least one of the plurality of
projections.
[0012] In some embodiments, the sole structure further may include an outer sole component.
According to the invention, the outer sole component includes an outer flex structure,
such as a groove or cut-out portion that may be aligned in registration with a flex
structure of the midsole component.
[0013] In another aspect, an article of footwear includes an upper and a sole structure
associated with the upper. The sole structure includes at least one fluid-filled chamber
component having a central portion, a plurality of lobes extending outward from the
central portion, and a plurality of channels formed between the plurality of lobes,
the plurality of channels extending in a direction from a top surface of the fluid-filled
chamber component to a bottom surface of the fluid-filled chamber component, and a
midsole component inter-fitted with the plurality of lobes of the fluid-filled chamber
component, a plurality of projections of the midsole component extending through the
plurality of channels of the fluid-filled chamber component, the midsole component
forming a portion of a peripheral side surface of the sole structure, wherein at least
a first lobe of the plurality of lobes has an exposed distal end wall including a
projecting portion that extends further outward from the central portion of the fluid-filled
chamber component than the portion of the peripheral side surface of the sole structure
formed by the midsole component.
[0014] In some embodiments, the protruding portion of the exposed distal end wall of at
least the first lobe may be formed by at least one facet of the exposed distal end
wall. The at least one facet may be disposed at an angle relative to the peripheral
side surface of the exposed side wall of the first projection. The peripheral side
surface formed by the exposed side wall may have a generally vertical configuration.
[0015] In some embodiments, at least one projection of the plurality of projections of the
midsole component may have an exposed side wall that forms a portion of the peripheral
side surface of the sole structure between exposed end walls of two adjacent lobes.
The exposed side wall of the at least one projection may be provided with flex structure,
such as a generally concave indentation or a plurality of recesses, e.g., arranged
in a recess pattern. A size, shape, and configuration of the flex structure may be
selected to structurally and/or visually complement the protruding portion of at least
one of the two adjacent lobes of the fluid-filled chamber component. This configuration
may facilitate compressibility, bending, and flexing of the sole structure at a location
between the two adjacent lobes of the fluid-filled chamber, as well as provide the
sole structure and article of footwear with a side profile that is aesthetically pleasing,
such as a "zig-zag" profile. Inter-fitted portions of the sole structure may be configured
to compress in a controlled manner when impact or ground reaction forces are applied
to the at least one fluid-filled chamber component, or when the sole structure is
flexed or bent at a flex structure of the sole structure, such that compression forces
are distributed in a controlled manner within the central portion and the plurality
of lobes of the fluid-filled chamber component by fluid within the fluid-filled chamber
component, e.g., causing one or more protruding portion(s) of the plurality of lobes
to distend. In this manner inter-fitted components of the sole structure may provide
improved performance characteristics, including a smooth response characteristic,
in the article of footwear. This inter-fitted construction enables customization of
compressibility of the sole structure by allowing certain predetermined portions of
the sole structure to expand and other portions of the sole structure to compress,
as desired, while providing improved flexibility and support in the sole structure.
[0016] In some embodiments, an optional outer sole component may include at least one outer
flex structure, such as a flex groove or a slot or opening in the outer sole component.
At least one projection of the inter-fitted construction may include a bottom surface
of the midsole component that may be exposed through a slot or opening in the outer
sole and configured with a flex structure to facilitate localized compression, bending,
and flexibility of the sole structure at the projection. In some embodiments, a projection
of the inter-fitted construction may include at least one flex structure, such as
a flex groove formed in an exposed bottom or lower surface of the midsole component,
that is configured to facilitate bending and flexibility of the sole structure.
[0017] In another aspect, a sole structure for an article of footwear is provided and includes
a midsole component having projections extending from a surface thereof, whereby the
projections each include a side wall that forms a peripheral side surface of the sole
structure. The sole structure additionally includes a fluid-filled chamber component
having a central portion, a plurality of lobes each including an end wall and extending
from the central portion, and a plurality of channels respectively formed between
the plurality of lobes that receive respective ones of the projections of the midsole.
The side walls of the projections cooperate with the end walls of the plurality of
lobes to form the peripheral side surface of the sole structure with a portion of
at least one of the end walls of the plurality of lobes extending further outward
from the central portion than side walls of the projections.
[0018] In one configuration, the plurality of channels may extend from a top surface of
the fluid-filled chamber component to a bottom surface of the fluid-filled chamber
component. Additionally, the projections may extend from the top surface of the fluid-filled
chamber component to the bottom surface of the fluid-filled chamber component and/or
the projections may extend through the fluid-filled chamber component at the plurality
of channels.
[0019] The side walls of the projections may taper down in a direction extending from the
surface of the midsole toward the fluid-filled chamber component and/or the end walls
of the lobes may taper down in a direction extending from the bottom surface of the
fluid-filled chamber component to the top surface of the fluid-filled chamber component.
[0020] At least one of the projections may include a flex structure formed into the side
wall. The flex structure may be at least one of recess and a horizontal groove, whereby
the horizontal groove is formed into the side wall within the recess.
[0021] An outer sole component may be attached to at least one of the midsole and the fluid-filled
chamber component. At least one of the projections may include a distal end that extends
through the fluid-filled chamber component and is attached to the outer sole component.
At least one of the projections may include a distal end that extends through the
fluid-filled chamber component and includes a flex groove formed therein, whereby
the flex groove is exposed at the outer sole component. The outer sole component may
include a cut-out that is aligned with the flex groove to expose the flex groove at
the outer sole component.
[0022] In another aspect, a method of making a sole structure for an article of footwear
according to appended claim 13 is provided and includes shaping a first sheet of material
to form a top surface of a chamber component, shaping a second sheet of material to
form a bottom surface of the chamber component, and joining the first sheet of material
and the second sheet of material to form a fluid-filled chamber component having a
central portion, a plurality of lobes each including an end wall and extending from
the central portion, and a plurality of channels respectively formed between the plurality
of lobes. The method additionally includes forming a midsole component including projections
extending from a surface thereof, the projections each including a side wall. The
projections are inserted into respective ones of the channels of the fluid-filled
chamber component to form a peripheral side surface of the sole structure comprised
of the end walls of the plurality of lobes and the side walls of the projections.
In one configuration, forming the fluid-filled chamber component includes causing
a portion of at least one of the end walls of the plurality of lobes to extend further
outward from the central portion than side walls of the projections.
[0023] The method may additionally include attaching a distal end of at least one of the
projections to an outer sole component and/or extending a distal end of at least one
of the projections through the fluid-filled chamber component to expose the distal
end of the at least one projection at an outer sole component.
[0024] Each of the above aspects, embodiments, and features may improve at least one performance
characteristic of a sole structure of an article of footwear. In particular, these
aspects and features, alone and/or in combination, variously may facilitate a smooth
response characteristic in a sole structure of an article of footwear, where bending
of the sole structure, particularly bending of a midsole of the sole structure, occurs
smoothly and without buckling. Further, these aspects, embodiments, and features variously
may be combined with one another and/or with other aspects, embodiments, and features
to improve overall performance of a sole structure of an article of footwear.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Embodiments may be better understood with reference to the following drawings and
detailed description. Elements, components, and features of the embodiments in the
figures are not necessarily drawn to scale, emphasis instead being placed upon illustrating
principles of the embodiments disclosed. In the figures, like reference numerals designate
like or corresponding parts or features throughout the different views, with the initial
digit(s) of each reference numeral indicating a figure in which the reference numeral
first appears.
FIG. 1 is a perspective view of an embodiment of an article of footwear including
a sole structure having a midsole component, a fluid-filled chamber component, and
an outsole component having an inter-fitted configuration;
FIG. 2 is an exploded perspective view of an embodiment of a sole structure including
a midsole component, a fluid-filled chamber component, and an outer sole component
having an inter-fitted configuration, as viewed from a bottom and lateral side;
FIG. 3 is a side elevation view of an embodiment of an assembled sole structure of
FIG. 2, with an enlarged partial view showing details of a portion of a midsole component
inter-fitted with a fluid-filled chamber component and an outsole component;
FIG. 4 is a perspective view of an embodiment of a fluid-filled chamber component
located in a heel region of a sole structure of FIG. 2;
FIG. 5 is a side elevation view of the fluid-filled chamber component of FIG. 4;
FIG. 6 is a cross-sectional view of the fluid-filled chamber component of FIG. 5,
taken along section line 6-6 of FIG. 5;
FIG. 7 is a perspective view of an embodiment of a fluid-filled chamber component
located in a forefoot region of a sole structure of FIG. 2;
FIG. 8 is side elevation view of the fluid-filled chamber component of FIG. 7;
FIG. 9 is a cross-sectional view of an embodiment of the fluid-filled chamber component
of FIG. 8, taken along section line 9-9 of FIG. 8;
FIG. 10 is a perspective view of an embodiment of a midsole component of the sole
structure of FIG. 2;
FIG. 11 is bottom plan view of an embodiment of an assembled sole structure of FIG.
3; and
FIG. 12 is a side elevation view of an embodiment of an assembled sole structure of
FIG. 3, with an enlarged partial view showing details of a portion of a midsole component
inter-fitted with a fluid-filled chamber component and an outsole component in a flexed
configuration.
DETAILED DESCRIPTION
[0026] The following description and accompanying figures disclose embodiments of articles
of footwear incorporating fluid-filled chamber components. Features and concepts related
to the footwear, and more particularly to the fluid-filled chamber components and
sole structure, are disclosed with reference to athletic footwear having a configuration
that is suitable for running. The embodiments are not limited to athletic footwear
configured for running, however, and may be applied to a wide range of footwear styles.
For example, features and concepts of the embodiments may be applied to other athletic
footwear, including basketball shoes, cross-training shoes, walking shoes, tennis
shoes, soccer shoes, hiking boots, and other athletic footwear. Features and concepts
of the embodiments also may be applied to non-athletic footwear styles, including
dress shoes, loafers, sandals, work boots, and other non-athletic footwear. One skilled
in the relevant art will appreciate that features and concepts of the disclosed embodiments
may apply to a wide variety of footwear styles, in addition to the specific styles
discussed in the following material and depicted in the accompanying figures.
[0027] Sole structures according to embodiments described herein may provide certain desirable
improvements in one or more performance characteristics of athletic footwear or other
articles of footwear. One such performance characteristic is known in the art as a
"smooth response" characteristic, meaning that bending of the sole structure, particularly
bending of a midsole component of the sole structure, occurs smoothly and without
buckling. Embodiments described herein variously may facilitate or improve compressibility,
bending, and flexibility of certain elements of a sole component and a sole structure
as a whole. Embodiments described herein may facilitate efficient manufacture of sole
structures and articles of footwear. And embodiments described herein may provide
an esthetically pleasing footwear design.
[0028] A sole structure including a midsole component formed of foam material, such as a
polymer foam material having a plurality of open or closed cells, may provide cushioning
and attenuate impact and ground reaction forces and other forces under a load. A polymer
foam material component may be configured to provide a comfortable fit, e.g., by conforming
to various contours of the foot.
[0029] A sole structure including a fluid-filled chamber component may provide cushioning
and attenuate impact and other ground reaction forces and other forces under a load.
A fluid-filled chamber component may be formed from a polymer material that is sealed
to enclose a fluid. Manufacturing techniques for making a fluid-filled chamber component
suitable for footwear applications may include a two-film technique, a thermoforming
technique, or a blow-molding technique.
[0030] A fluid-filled chamber component may be combined with a foam material component to
form a component of a sole structure. For example, in some embodiments a fluid-filled
chamber component may be located above a polymer foam material component, a fluid-filled
chamber component may be located below a polymer foam material component, and/or a
fluid-filled chamber component may be encapsulated within a polymer foam material
component. A fluid-filled chamber component combined with a polymer foam material
component may decrease a rate and/or effect of deterioration of the polymer foam material
component of the sole structure caused by repeated compression of the polymer foam
material by impact or other ground reaction forces during use of the article of footwear.
[0031] A fluid-filled chamber component may be combined with other midsole components to
provide improved attenuation response to impact and ground reaction forces, to provide
a range of customization in a sole structure, and/or to provide a pleasing aesthetic
appearance of the sole structure and article of footwear.
[0032] FIG. 1 illustrates an embodiment of an article of footwear 100 that includes an upper
102 and a sole structure 103. As shown in FIG. 1, in some embodiments sole structure
103 may include a midsole component 104, a fluid-filled chamber component 106, and
an optional outer sole component 108.
[0033] Upper 102 may have any configuration suitable for a desired article of footwear.
Upper 102 may include one or more material element, such as textiles, foam materials,
and leather materials that may be stitched or adhesively bonded together. The one
or more material elements may be manipulated or configured to form an interior of
upper 102 for securely and comfortably receiving a foot.
[0034] Sole structure 103 may include plural components. In some embodiments sole structure
103 generally may include a midsole component 104, a fluid-filled chamber component
106, and an optional outer sole 108. Sole structure 103 may be secured to a lower
surface of upper 102, such as by stitching or adhesive bonding. Fluid-filled chamber
component 106 may be attached to midsole component 104, such as by adhesive bonding.
And outer sole 108 may be secured to midsole component 104 and/or fluid-filled chamber
component 106, such as by adhesive bonding. Sole structure 103 further may include
an optional insole or inner sole (not shown), which may be a thin cushioning member
typically located within the interior of upper 102 and adjacent to the foot to enhance
the comfort of article of footwear 100. Those skilled in the art will appreciate alternative
materials for, and methods suitable for attaching, upper 102, midsole component 104,
fluid-filled chamber component 106, and optional outer sole 108 consistent with descriptions
of embodiments herein.
[0035] Sole structure 103 generally operates to attenuate impact and other ground reaction
forces and absorb energy, e.g., as sole structure 103 contacts a ground surface during
active use.
[0036] As shown in FIG. 1, in some embodiments midsole component 104 may be located adjacent
a foot when the foot is disposed in an interior of the upper 102. In some embodiments,
midsole component 104 generally may be configured to conform to contours of the foot,
and to provide the foot with cushioning during walking, running, or other activities.
In some embodiments, midsole component 104 may be made of a foam material having an
open or closed cell foam material construction. In some embodiments, midsole component
104 may be formed of a polymer foam material, such as polyurethane or ethylvinylacetate.
In some embodiments, midsole component 104 may be made by any manufacturing method
suitable for making a foam material component. For example, in some embodiments midsole
component 104 may be made by injection molding a polymer foam material.
[0037] As shown in FIG. 1, in some embodiments fluid-filled chamber component 106 generally
may be disposed between midsole component 104 and optional outer sole component 108.
Fluid-filled chamber component 106 may be made of any material suitable for holding
a desired fluid in a sole construction. In some embodiments, fluid-filled chamber
component 106 may be made of a polymer material that is substantially impermeable
to fluid within a closed chamber of fluid-filled chamber component 106. In some embodiments,
fluid-filled chamber component 106 may be made of a thermoplastic elastomer.
[0038] Fluid-filled chamber component 106 may be manufactured using a variety of techniques.
For example, in some embodiments fluid-filled chamber component 106 may be made by
blow molding, thermoforming, rotational molding, or other molding processes.
[0039] As shown in FIG. 1, in some embodiments midsole component 104 may be inter-fitted
with fluid-filled chamber component 106 in a manner that presents a sole structure
103 and article of footwear 100 having an aesthetically pleasing side profile. As
shown in FIG. 1, in some embodiments midsole component 104 may be inter-fitted with
fluid-filled chamber component 106 in a manner that presents a sole structure 103
and article of footwear 100 having a generally "zigzag" pattern side profile.
[0040] As shown in FIG. 1, optional outer sole component 108 generally may be configured
to engage a ground surface and impart traction to article of footwear 100. In some
embodiments, outer sole component 108 may be formed of a durable, wear-resistant material
that is configured to engage a ground surface and impart traction. In some embodiments,
outer sole component 108 may include at least one traction element configured to engage
a ground surface and impart traction.
[0041] Hensley et al., U.S. Patent Number 7,128,796, issued October 31, 2006, and entitled "FOOTWEAR WITH A SOLE STRUCTURE INCORPORATING A LOBED FLUID-FILLED
CHAMBER," the entirety of which is hereby incorporated herein by reference, discloses
general aspects, features, and techniques of construction and manufacture of various
components and elements of a sole structure that may be included in some aspects of
some embodiments of the present disclosure. Those skilled in the art will be able
to select suitable materials and techniques for making embodiments described herein
in view of these descriptions and disclosures.
[0042] Referring to FIG. 1, article of footwear 100 generally includes a heel region 110,
a mid-foot region 112, and a forefoot region 114 including a toe region 116. Article
of footwear 100 further may include a medial side 118 and a lateral side 120. In this
disclosure, references to heel region 110, mid-foot region 112, forefoot region 114,
toe region 116, medial side 118, and lateral side 120 do not refer to exact structures
or boundaries, but rather generally designate regions or areas of article of footwear
100. In some aspects, these regions or areas may overlap. It will be appreciated that
references to heel region 110, mid-foot region 112, forefoot region 114, toe region
116, medial side 118, and lateral side 120 also may apply to various elements or components
of article of footwear 100, such as upper 102, sole structure 103, midsole component
104, fluid-filled chamber component 106, and optional outer sole component 108. Further,
the term lateral may be used to describe a medial-lateral direction or orientation
of article of footwear 100 or a component or portion of article of footwear 100. Similarly,
the terms rear or proximal and the terms front, forward, or distal may be used to
describe a direction, orientation, or relative location along a direction from heel
region 110 to toe region 120 of article of footwear 100 or a component or portion
of article of footwear 100. Similarly, the term vertical may be used to describe a
direction perpendicular to a ground surface when article of footwear 100 is disposed
with its sole structure 103 laying substantially flat on the ground surface. Those
skilled in the art will be able to interpret these references and relative terms throughout
the disclosure and claims based on the context in which these references and terms
are used in the disclosure and claims.
[0043] FIGS. 2 and 3 illustrate an embodiment of a sole structure 200. FIG. 2 is an exploded
view of sole structure 200, viewed from a bottom and lateral side of the sole structure
200. FIG. 3 is a lateral side profile view of assembled sole structure 200, and includes
an enlarged partial view showing details of a portion of inter-fitted components and/or
elements of sole structure 200. In some embodiments, sole structure 200 may correspond
to sole structure 103 in FIG. 1.
[0044] As shown in FIG. 2, in some embodiments sole structure 200 may include a midsole
component 204, a fluid-filled chamber component 206, and an optional outer sole component
208. In some embodiments, as discussed below, midsole component 204, fluid-filled
chamber component 206, and optional outer sole component 208 may be configured to
be inter-fitting to achieve an assembled sole structure 200, as shown in FIGS. 2 and
3. In some embodiments, midsole component 204, fluid-filled chamber component 206,
and optional outer sole component 208 may be inter-fitted in manufacture to form assembled
sole structure 200. For example, in some embodiments fluid-filled chamber component
206 and optional outer sole component 208 may be manufactured separately and layed
up in a mold cavity of a molding system for molding a sole structure, and inter-fitted
midsole component 204 may be formed by injection molding a molding material, such
as a polymer foam material, into the mold cavity of the molding system, including
the layed up sole component(s), to achieve a sole structure 200 having an inter-fitted
configuration. In some embodiments, midsole component 204, fluid-filled chamber component
206, and optional outer sole component 208 may be manufactured separately, such as
by various molding processes using separate molding systems and mold materials, and
then bonded together in an inter-fitted configuration to form an assembled sole structure
200.
[0045] Midsole component 204 includes at least one midsole component or element. As shown
in FIG. 2, in some embodiments midsole component 204 may be a single midsole component
or element. In some embodiments, midsole component 204 may be formed of a foam material,
such as a polymer foam material having an open or closed cell foam structure. The
foam material may beneficially compresses resiliently under an applied load. In some
embodiments, midsole component 204 may be formed of a material that is mold compatible
or otherwise suitable for bonding with fluid-filled chamber component 206 and/or optional
outer sole component 208, such as by adhesive or thermal bonding. As further discussed
below, midsole component 204 may include a plurality of projections, such as projections
240, 242, 244, and 246 that may be inserted through and inter-fitted with structures
of fluid-filled chamber component 206 and/or outer sole component 208. In some embodiments,
at least some of plurality of projections 240, 242, 244, and 246 may be provided with
exposed side walls 248 having flex structures 247 for facilitating localized compression,
bending, or flexing of sole structure 200 and article of footwear 100. In some embodiments,
flex structures 247 may have a concave surface and/or a plurality of generally horizontal
grooves 310 formed into exposed side walls 248 that may provide a desired compressibility
and/or flexibility of midsole component 204 at flex structure 247.
[0046] In some embodiments, at least some of plurality of projections 240, 242, 244, 246
may be provided with flex structures 249 at distal ends of the projections for facilitating
localized compression, bending, and flexing of sole structure 200 and article of footwear
100. In some embodiments, flex structures 249 may include a flex groove or sipe that
may provide a desired compression or flexibility of midsole 204 at flex structure
249. The flex groove or sipe may be exposed at the outer sole component 208, as shown
in FIG. 3.
[0047] Fluid-filled chamber component 206 may include one or more fluid-filled chamber components
or elements. In some embodiments, multiple fluid-filled chamber components or elements
having different characteristics, e.g., having different sizes, configurations, volumes,
fluids, pressures, or other compression or performance characteristics, may be provided
in respective impact zones of an article of footwear. Such a configuration may enable
customization of compression characteristics of the fluid-filled chamber components
and associated performance characteristics of sole structure 200 and article of footwear
100.
[0048] As shown in FIG. 2, for example, in some embodiments fluid filled chamber component
206 may include a first fluid-filled chamber component 210 located in heel region
110 of sole structure 200 (hereafter also referred to as heel chamber 210) and a second
fluid-filled chamber component 220 located in forefoot region 114 of sole structure
200 (hereafter also referred to as forefoot chamber 220). Heel chamber 210 may be
configured to provide inflation and performance characteristics suitable for attenuating
impact and ground reaction forces associated with a heel region of article of footwear
100, such as a heel strike portion of a running stride. Forefoot chamber 220 may be
configured to provide inflation and performance characteristics suitable for stabilizing
reaction forces, such as forces associated with pronation or forces associated with
changing lateral directions during a running stride. Those skilled in the art will
be able to select a number, configuration, and arrangement of fluid-filled chamber
component(s) suitable for desired performance characteristics of a sole structure
in view of the present disclosure.
[0049] Outer sole component 208 may include one or more outer sole components. As shown
in FIG. 2, in some embodiments outer sole component 208 may include a first outer
sole component 230 located in heel region 110 of sole structure 200, a second outer
sole component 232 generally located in heel region 110 and midfoot region 112 of
sole structure 200, a third outer sole component 234 generally located in midfoot
region 112 and forefoot region 114 of sole structure 200, and a fourth outer sole
component 236 generally located in toe region 116 of sole structure 200. In some embodiments,
outer sole components 230, 232, 234, and 236 may be separate elements. In some embodiments,
two or more of outer sole components 230, 232, 234, and 236 may be connected to one
another, e.g., integrally molded together as a single piece. For example, as shown
in FIG. 2, in some embodiments outer sole component 230 and outer sole component 232
may be connected at flex groove 231, with outer sole component 230 being generally
disposed in a heel strike area of heel region 230; in some embodiments outer sole
component 232 and outer sole component 234 may be connected at flex groove 233. In
some embodiments, other outer sole components may have different configurations, shapes,
or sizes. In some embodiments, one or more of outer sole components 230, 232, 234,
and 236 may be optional. In some embodiments, outer sole component 208 may be optional.
[0050] Outer sole component 208 generally may be disposed below midsole component 204 and
fluid-filled chamber component 206, and may be formed of an abrasion resistant material
suitable for contact with a ground surface. For example, outer sole component 208
may be disposed below midsole component 204 and fluid-filled chamber component 206
in heel region 110 to protect these components from abrasive contact with a ground
surface in heel region 110, e.g., during a heel strike of a running stride. Similarly,
outer sole component 208 may be disposed below midsole component 204 and/or fluid-filled
chamber component 206 in forefoot region 114, e.g., below the metatarsals or balls
of the foot, to protect these components from abrasive contact with a ground surface,
e.g., during a pivot motion.
[0051] In some embodiments, outer sole component 208 may include one or more outer flex
structures that may cooperate with one or more flex structures of inter-fitted midsole
component 204 and/or fluid-filled chamber component 206 to facilitate localized compression,
bending, and flexing of sole structure 200. For example, outer sole component 208
may include one or more groove portions 231, 233 in heel region 110 and/or midfoot
region 112, respectively, to facilitate localized compression, bending or flexing
of sole structure 200 in heel region 110 and/or midfoot region 112. Similarly, in
some embodiments outer sole component 208 may include one or more cut-out portions,
such as cut-out portions 235, 237 located in forefoot region 114, to facilitate localized
compression, bending or flexing of sole structure 200 in forefoot region 114. For
example, in some embodiments one or more pairs of cut-out portions 235 may be provided
on opposing medial and lateral sides of outer sole 208, with a connecting portion
of outer sole 208 disposed between the cut-out portions. The cut-out portions 235
may be aligned with the flex grooves or sipes of flex structure 247 to expose the
flex grooves or sipes at the outer sole component 208. In some embodiments, a cut-out
portion may be provided from a medial to lateral side of outer sole 208, such as cut-out
portion 237, thereby defining two or more separate outer sole components. In some
embodiments, outer sole 208 may include one or more traction elements 239 for providing
traction with a ground surface or other external surface (e.g., a soccer ball).
Fluid-Filled Chamber Component Features
[0052] As discussed above, fluid-filled chamber component 206 may include one or more fluid
filled chamber components. For example, as shown in FIG. 2, in some embodiments fluid-filled
chamber component 206 may include a heel chamber 210 and a forefoot chamber 220.
Heel Chamber Features
[0053] FIGS. 4, 5, and 6 illustrate embodiments of a fluid-filled chamber component 400
suitable for use as heel chamber of a sole structure. FIG. 4 is a perspective view
of fluid-filled chamber 400. FIG. 5 is a side elevation view of fluid-filled chamber
component 400. And FIG. 6 is a cross-sectional view of fluid-filled chamber component
400, taken along section line 6-6 of FIG. 5. In some embodiments, fluid-filled chamber
component 400 may correspond to heel chamber 210 of sole structure 200 in FIG. 2.
Accordingly, elements of fluid-filled chamber component 400 may be indicated by reference
numbers of corresponding elements for heel chamber 210 of sole structure 200 in FIG.
2 to describe certain features of fluid-filled chamber component 400.
[0054] As shown in FIG. 4, in some embodiments fluid-filled chamber component 400 (e.g.,
heel chamber 210) may be a single chamber bladder construction that includes a central
portion 410 and a plurality of lobes 420 (421, 422, 423, 424, 425, 426) that extend
outward from central portion 410. In some embodiments, the plurality of lobes 420
may extend in selected directions around a heel region 110 of sole structure 200 and
article of footwear 100. In some embodiments, fluid-filled chamber component 400 may
include a plurality of channels 440 (441, 442, 443, 444, 445, 446), each generally
defined on three sides by central portion 410 and respective pairs of adjacent lobes
of plurality of lobes 420. As shown in FIG. 4, and as further discussed below, each
of the plurality of channels 440 may be open at a side opposite central portion 410
(e.g., each channel 420 may have a side opening opposite the central portion 410 of
fluid-filled chamber portion 400). As discussed further below, this configuration
may facilitate inter-fitting midsole component 204 with fluid-filled chamber component
400. This configuration also may enable midsole component 204 to form a portion of
a peripheral side surface of sole structure 200 at side openings of plurality of channels
420. In some embodiments, a configuration of midsole component 204 with heel chamber
210 (400) may selected to provide a desired ratio of fluid to foam in specific areas
under the heel portion.
[0055] Fluid-filled chamber component 400 includes a top or upper surface 411 and a bottom
or lower surface 412. As shown in FIG. 4, in some embodiments top surface 411 may
have a generally concave configuration. In some embodiments, top surface 411 may include
a raised central portion 414. In some embodiments, the central portion 414 may include
a portion defined by an angled perimeter portion 413. In some embodiments, angled
perimeter portion 413 and raised central portion 414 may have a configuration, including
at least size and shape, that generally conforms to a configuration of central portion
410. In some embodiments, raised portion 414 may have a regular or non-regular geometric
shape, such as a circle, an oval, a rectangle, a hexagonal, or other regular or non-regular
geometric shape. This configuration, including a raised central portion 414, may provide
a deeper cushion, which may help provide improved cushioning of impact forces, e.g.,
heel strike forces, and/or lateral stability of fluid-filled chamber component 400,
e.g., distribution of internal pressure forces in fluid-filled chamber component 400.
In some embodiments, providing fluid-filled chamber component 400 with a raised central
portion 414 having a selected regular or non-regular geometric shape may facilitate
assembly of sole structure 200 including fluid-filled chamber component 400 and another
component of sole structure 200 having a mating surface geometry, such as midsole
component 204 of sole structure 200.
[0056] Bottom surface 412 may present a generally flat or planar surface to facilitate manufacture
and assembly. For example, in some embodiments a bottom surface 412 having a generally
flat or planar surface may facilitate secure attachment of fluid-filled chamber component
400 to outer sole component 208, e.g., by adhesive or thermal bonding.
[0057] Fluid-filled chamber component 400 may include a fill tube 450 in fluid communication
with an interior of fluid-filled chamber component 400. In some embodiments, fill
tube 450 may be sealed during manufacture of fluid-filled chamber component 400. In
some embodiments, fill tube 450 may be used to charge the interior of fluid-filled
chamber component 400 with desired fluid at a desired pressure during and/or after
manufacture of fluid-filled chamber component 400.
[0058] A number and configuration of plurality of lobes 420 may vary based on various factors
including, but not limited to, desired cushioning and performance characteristics
of heel chamber 210 and sole structure 200. As shown in FIG. 4, in some embodiments
fluid-filled chamber component 400 may have six lobes 420, including three lobes (421,
422, 423) generally located on a medial side of heel chamber 210, and three lobes
(424, 425, 426) generally located on a lateral side of heel chamber 210. In this configuration,
two lobes 423 and 424 may be located in a rear heel region of sole structure 200.
This number and general configuration may provide desired cushioning, balance, stability,
and/or other performance characteristics for fluid-filled chamber component 400. In
some embodiments, plurality of lobes 420 may extend from central portion 410 in different
selected directions to achieve desired cushioning, balance, stability, and/or performance
characteristics. A number and configuration of plurality of lobes 420 also may be
selected to provide a pleasing aesthetic profile, as discussed herein. Those skilled
in the art will be able to select a desired number and configuration of lobes 420
suitable for achieving a sole structure and article of footwear having desired performance
and aesthetic characteristics based on the present disclosure.
[0059] At least some of plurality of lobes 420 may include a distal end wall 430 that is
configured to be exposed at a peripheral side surface of a sole structure, such as
sole structure 200 of FIG. 2. As shown in FIG. 4, in some embodiments each of plurality
of lobes 420 (421, 422, 423, 424, 425, 426) may have an exposed distal end wall 430
(431, 432, 433, 434, 435, 436) that is configured to form a portion of a peripheral
side surface of sole structure 200 (see also, e.g., sole structure 103 in FIG. 1 and
assembled sole structure 200 in FIG. 3).
[0060] Plurality of lobes 420 may have similar or different sizes and shapes. As shown in
FIGS. 4, 5, and 6, in some embodiments at least some of plurality of lobes 420 (421,
422, 423, 424, 425, 426) generally may have similar sizes and/or shapes. For example,
as shown in FIG. 4, plurality of lobes 420 (421, 422, 423, 424, 425, 426) may have
similar shapes in top plan view and in bottom plan view, e.g., generally wedge shapes
that expand in a direction away from central portion 410 (see also, e.g., plurality
of lobes 216 of heel chamber 210 in FIG. 2). Similarly, plurality of lobes 420 may
have similar geometries in cross-section and/or similar shapes and geometries at exposed
distal end walls 430. For example, as shown in FIGS. 4 and 5, in some embodiments
each of plurality of lobes 420 (421, 422, 423, 424, 425, 426) may have a cross-section
having a generally trapezoidal shape and an exposed distal end wall 430 (431, 432,
433, 434, 435, 436) having a generally trapezoidal shape. As shown in FIG. 5, for
example, in some embodiments exposed distal end wall 435 of lobe 425 may have a width
X1 (510) at top surface 411 and a width X2 (512) at bottom surface 412, where width
X2 is greater than width X1 (distance X2 > distance X1) such that distal end wall
435 tapers down in a direction extending from the bottom surface 412 to the top surface
411. As shown in FIG. 2, in some embodiments shapes of plurality of lobes 420 may
be similar but vary in size so as to follow general contours of an assembled sole
structure (see, e.g., plurality of lobes 216 and 226 of sole structure 200). It will
be appreciated that plurality of lobes 420 (421, 422, 423, 424, 425, 426) may have
similar or different cross-sectional and/or exposed distal end walls of other geometric
shapes. For example, in some embodiments plurality of lobes 420 may have generally
triangular shapes. It will be appreciated that the generally triangular shapes may
provide a sole structure having a side profile that presents a visually pleasing zig-zag
surface configuration.
[0061] Plurality of channels 440 located between plurality of lobes 420 likewise may have
similar or different sizes and shapes. It will be appreciated that, because plurality
of channels 440 (441, 442, 443, 444, 445, 446) are formed by adjacent pairs of plurality
of lobes 420 (421, 422, 423, 424, 425, 426), each of plurality of channels 420 generally
has a geometry at opposing sides that is complementary to the geometry of its adjacent
pair of plurality of lobes 420. For example, as shown in FIG. 4, in some embodiments
channel 445 located between lobe 425 and lobe 426 has a width W1 (460) at bottom surface
412 and a width W2 (462) at top surface 411, where width W2 is greater than width
W1 (distance W2 > distance W1) such that channel 445 tapers down in a direction extending
from top surface 411 to bottom surface 412. Thus, as shown in FIGS. 2 to 5, in some
embodiments cross-sections of plurality of channels 440 (441, 442, 443, 444, 445,
446) defined between adjacent lobes of plurality of lobes 420 along a direction away
from central portion 410 generally have trapezoidal shapes that are inverted (upside
down) relative to trapezoidal shapes of congruent cross-sections of adjacent pairs
of plurality of lobes 420. It will be appreciated that plurality of channels 440 (441,
442, 443, 444, 445, 446) may have cross-sections of other geometric shapes. For example,
in some embodiments plurality of channels 440 (441, 442, 443, 444, 445, 446) may have
cross-sections of generally triangular shapes, which also are complementary to congruous
trapezoidal cross-sectional shapes of respective adjacent pairs of plurality of lobes
420. It will be appreciated that plurality of channels having cross-sections of generally
triangular shapes also may provide a sole structure presenting a side profile having
a visually pleasing zig-zag surface configuration.
[0062] As shown in FIG. 4, in some embodiments each of plurality of channels 441, 442, 443,
444, and 445 may have a generally truncated conical shape with an axis extending in
a direction from top surface 411 of fluid-filled chamber component 400 to bottom surface
412 of fluid-filled chamber component 400. Similarly, in some embodiments channel
446 generally may form half of a truncated conical shape between lobes 421 and 426.
As discussed below with respect to inter-fitted projections of midsole component 204,
at least some of plurality of channels 440 (441, 442, 443, 444, 445, 446) may have
a generally conical shape with a generally truncated oval or elliptical horizontal
cross-section, e.g., along a lateral direction of sole structure 200.
[0063] It will be appreciated that, while the above embodiments illustrate and describe
plurality of lobes 420 and plurality of channels 430 having cross-sectional walls
and boundaries that correspond to continuous surfaces (i.e., plurality of lobes 420
generally have continuous smooth surfaces defining plurality of channels 440 having
generally continuous smooth boundary surfaces), in some embodiments plurality of lobes
420 may have discontinuous, stepped, or non-smooth surfaces defining corresponding
plurality of channels 440 that have complementary discontinuities, steps, or non-smooth
surfaces. Smooth or continuous surface configurations may have advantages in some
embodiments, e.g., in ease of manufacture or assembly of sole structure 200. Non-smooth,
stepped, or discontinuous surface configurations may have advantages in other embodiments.
Those skilled in the art will be able to select desired surface characteristics suitable
for a desired embodiment or application.
[0064] According to the invention, at least one of plurality of exposed distal end walls
430 of plurality of lobes 420 may have a protruding portion and at least one exposed
distal end wall 430 is faceted with a protruding portion, such as a facet edge. As
shown in FIGS. 4 and 5, according to the invention, each of plurality of lobes 420
has an exposed distal end wall 430 (431, 432, 433, 434, 435, 436) that is faceted
with a protruding portion (see also protruding portions of plurality of lobes 216
and 226 in FIGS. 2 and 3, and protruding portions 106 of sole structure 103 in FIG.
1). As used in this description and in the claims, the term facet and/or faceted generally
refers to surface structure including a first surface portion of the exposed distal
end wall 430 that forms an edge with at least one second surface portion of the exposed
distal end wall 430, where one or both of the first surface portion and the second
surface portion may be straight (e.g., generally flat or planar) or curved. For purposes
of brevity and simplicity, features of embodiments of one exposed distal end wall
(exposed distal end wall 435 of lobe 425) having a protruding portion will be described
below. Those skilled in the art readily will be able to provide similar protruding
portion features for some or all of plurality of lobes 420.
[0065] According to the invention, at least one facet of an exposed distal end wall is arranged
or oriented at an angle relative to a peripheral side surface of sole structure 200
(e.g., angled relative to vertical or relative to another portion of a peripheral
side surface of sole structure 200), such that a facet edge formed between the first
surface portion and the second surface portion of the exposed distal end wall protrudes
further than other portions of the exposed distal end wall in an exposed direction
extending in a direction away from the central portion 410 relative to the peripheral
side surface of sole structure 200. In some embodiments, a peripheral side surface
of sole structure 200 may be generally vertical. In other embodiments, a peripheral
side surface of sole structure 200 may be inclined relative to vertical, either inward
or outward in a direction from top surface 411 of the fluid-filled chamber component
400.
[0066] As shown in FIGS. 4 to 6, according to the invention, exposed distal end wall 435
includes a first facet 455 and a second facet 456, where first facet 455 has a generally
trapezoidal shape and is oriented at an angle [alpha] 615 (see, FIG. 6) relative to
vertical such that first facet 455 and second facet 456 form a facet edge or protruding
portion 457 having three sides in the form of a generally trapezoidal arch. In some
embodiments, protruding portion or facet edge 457 may occur at a smooth transition
between first surface portion or facet 455 and second surface portion or facet 456
that provides a gently rounded contour that may provide increased flexibility in the
protruding portion of the exposed distal end wall. As shown in FIGS. 4 to 6, in some
embodiments this configuration may be made by a molding process that molds opposing
first and second sheets of mold material to form top surface 411 and bottom surface
412 of fluid-filled chamber 400, respectively, where the first (top) and second (bottom)
sheets are joined, e.g., by co-molding or thermal bonding, at a parting line that
forms facet edge or protruding portion 457. Methods for making fluid-filled chambers
and other elements of a sole structure which may be included in some aspects of some
embodiments of the present application, are disclosed in
Schindler et al., U.S. Patent Number 7,707,745, issued May 4, 2010, and entitled "FOOTWEAR WITH A SOLE STRUCTURE INCORPORATING A LOBED FLUID-FILLED
CHAMBER", the entirety of which is hereby incorporated by reference.
[0067] As shown in FIG. 6, common protruding portion or facet edge 457 may form a furthest
protruding portion of exposed distal end wall 435 in a direction extending away from
central portion 410. As shown in FIGS. 4 to 6, each of plurality of lobes 420 generally
may have a similar construction and configuration. It will be appreciated that in
some embodiments this construction and configuration may provide a continuous parting
line between a first sheet of mold material forming top surface 411 and a second sheet
of mold material forming bottom surface 412 that follows consecutive trapezoidal shaped
protruding portions or facet edges (see, e.g., protruding portion or facet edge 457)
of plurality of lobes 420 of fluid-filled chamber component 400, and presents a generally
zig-zag surface profile configuration. It will be appreciated that this configuration
may be used to make an assembled sole structure 200 that presents a peripheral side
surface having an aesthetically pleasing zig-zag surface profile configuration (see,
e.g., FIGS. 1 and 3).
[0068] In some embodiments, a parting line between a first sheet of mold material forming
top surface 411 and a second sheet of mold material forming bottom surface 412 alternatively
may be located at a top of exposed distal end wall 430 of plurality of lobes 420.
In this configuration, the parting line may be located further inward toward central
portion 410 of heel chamber 400 than the furthest protruding portion of each of plurality
of lobes 420 (e.g., protruding facet edge 457), e.g., along a peak or highest vertical
location of each of plurality of lobes 420 at end wall 430. It will be appreciated
that this configuration may allow for the parting line to be concealed when assembled
with inter-fitted midsole component 204. That is, with this configuration, in some
embodiments the parting line of the plurality of lobes of heel chamber 210 (400) and
forefoot chamber 220 may be covered by midsole component 204.
[0069] In each of the above embodiments, a parting line between a first sheet of mold material
and a second sheet of mold material may be located along plurality of channels 440
on both (opposing) sides of plurality of lobes 420. In some embodiments, the parting
line may be located at or along the bottom surface 412 of fluid-filled chamber component
400. In some embodiments, the parting line may be located at an intermediate height
along each lobe or along a top surface 411 of fluid-filled chamber component 400.
Those skilled in the art will be able to select a location of a parting line suitable
for a desired molding process and/or construction and configuration of sole structure
200 and article of footwear 100.
[0070] A configuration of sole structure 200 including a plurality of lobes (216, 226, 420)
having a plurality of protruding portions may vary based on a number of factors, such
as manufacturing process and desired aesthetic profile. As shown in FIGS. 3, 4, and
5, for example, actual heights of furthest protruding portions or facet edges may
vary. In some embodiments, a furthest protruding height of each lobe of plurality
of lobes 420 may vary in proportion with overall heights of respective plurality of
lobes 420, which may vary with a contour of sole structure 200 (see, e.g., FIGS. 1
and 3). In some embodiments, a relative proportion of the height a furthest protruding
portion to the height of a lobe generally may be constant. This configuration may
provide consistent performance characteristics as well as a pleasing visual aesthetic
profile. In some embodiments, a height of a furthest protruding portion of a lobe
may be greater than 50% of a total height of the lobe. For example, as shown in FIG.
6, a height H2 (612) of common facet edge 457 of lobe 425 may be greater than 50%
of a height H1 (610) of exposed distal end wall 435 of lobe 425.
[0071] It will be appreciated that this configuration, including an exposed distal end wall
having a furthest protruding portion located at a height greater than 50% of a total
height of the exposed distal end wall of a lobe, may facilitate controlled stable
dispersion of compression forces in fluid contained within fluid-filled chamber 400,
e.g., due to an impact force during running. For example, impact/compression forces
created during a heel strike of a running stride, as indicated by arrows 618 in FIG.
6, may result in dispersion or channeling of compression forces outward from central
portion 410 through plurality of lobes 420 to exposed distal end walls 430, causing
distension of exposed and protruding portions of the exposed distal end walls (e.g.,
at facet edge 457 in FIG. 7) and a stabilizing dispersion of compression forces at
the exposed distal end walls, as indicated by arrows 620 in FIG. 6. This configuration
may reduce transfer of compression forces from fluid-filled chamber component 400
to foam material of adjacent inter-fitted midsole component 204, thereby reducing
deterioration of the foam material. Accordingly, this configuration may provide desired
stability characteristics and other performance characteristics in sole structure
200 and article of footwear 100.
[0072] At least one lobe of plurality of lobes 420 of fluid-filled chamber component 400
(e.g., heel chamber 210) may have a different configuration, including at least size
and/or shape, than other lobes of fluid-filled chamber component 400. As shown in
FIG. 4, for example, lobe 424 located in a rear lateral area of heel region 110 of
sole structure 200 (generally corresponding to an initial contact area of sole structure
200 and article of footwear 100 with a ground surface during a heel strike portion
of a running stride with normal pronation) may be configured with at least a greater
cross-sectional width and a greater width at exposed distal end wall 434 than other
lobes 420 of fluid-filled chamber component 400. As shown in FIG. 5, lobe 424 also
may be configured with an angled base portion 515 at a heel strike area, e.g., base
portion 515 of lobe 424 adjacent exposed distal end wall 434 may be angled up and
away from the ground surface in a direction away from central portion 410 of fluid-filled
chamber portion 400. The configuration of angled base portion 515, including at least
size, shape, and angle of base portion 515, may vary based on a number of factors.
For example a size, shape, or angle of base portion 515 may vary based on a size of
the article of footwear, wear characteristics of the sole components, pronation and
other characteristics of the user, and other desired performance characteristics of
sole structure 200 and article of footwear 100. Those skilled in the art will be able
to select a desired configuration of portion 515 including the size of angle θ, 516,
which may range from approximately 0 degrees to approximately 60 degrees, suitable
to provide a smooth heel strike motion and desired performance characteristics of
the article of footwear.
[0073] As discussed further herein, in some embodiments an inter-fitted trapezoidal or triangular
cross-sectional configuration may facilitate control of localized compression, bending,
and flexibility of sole structure 200 between adjacent lobes 420, and provide improved
smooth response performance and other performance characteristics of sole structure
200 and article of footwear 100. Those skilled in the art will appreciate additional
geometric and/or non-geometric shapes suitable for achieving an inter-fitted configuration
having desired localized compression, bending, flexing, and other performance characteristics
and aesthetic profiles suitable for a particular embodiment.
Forefoot Chamber Features
[0074] FIGS. 7, 8, and 9 illustrate embodiments of a fluid-filled chamber component or element
700 suitable for use as forefoot chamber of a sole structure. FIG. 7 is a perspective
view of fluid-filled chamber 700. FIG. 8 is a side elevation view of fluid-filled
chamber component 700. And FIG. 9 is a cross-sectional view of fluid-filled chamber
component 700, taken along section line 9-9 of FIG. 8. In some embodiments, fluid-filled
chamber component 700 may correspond to forefoot chamber 220 of sole structure 200
in FIG. 2. Accordingly, elements of fluid-filled chamber component 700 may be indicated
by reference numbers of corresponding elements of forefoot chamber 220 to describe
certain features of fluid-filled chamber component 700.
[0075] Fluid-filled chamber component 700 may have a construction and configuration that
is substantially similar to fluid-filled chamber component 400. It will be appreciated
that fluid-filled chamber component 700 may have some differences in construction
and configuration from fluid-filled chamber 400 suitable for locating fluid-filled
chamber component in the forefoot region of sole structure 200 of article of footwear
100. For example, in some embodiments fluid-filled chamber component 700 may have
an overall profile that is lower than an overall profile of fluid-filled chamber component
400, consistent with an overall profile of sole structure 200 (see, e.g., FIG. 3).
In some embodiments, a configuration of midsole component 204 with forefoot chamber
220 (700) may be selected to provide a desired ratio of fluid to foam in specific
areas under the forefoot portion.
[0076] As shown in FIG. 7, in some embodiments fluid-filled chamber component 700 (e.g.,
forefoot chamber 220) may include a top or upper surface 710, a bottom or lower surface
712, a central portion 714 (generally shown by a dotted line), an optional fill tube
750, and a plurality of lobes 720 (721, 722, 723, 724, 725, 726) that extend outward
from central portion 714. As shown in FIG. 7, in some embodiments top surface 710
of fluid-filled chamber component 700 may be generally planar, with no raised portion
in central portion 714. In some embodiments, fluid-filled chamber component 700 may
include a plurality of channels 740 (741, 742, 743, 752, 753), each generally defined
on three sides by central portion 714 and respective pairs of adjacent lobes of plurality
of lobes 720. As shown in FIG. 7, each of plurality of channels 740 (741, 742, 743,
744, 752, 753) may be open at a side opposite central portion 714 (e.g., each channel
720 may have a side opening opposite the central portion 714 of fluid-filled chamber
portion 700). As shown in FIG. 7, fluid-filled chamber component 700 may include a
rear channel 752 generally formed between lobes 723 and 724, and a front channel 753
generally formed between lobes 721 and 726. It will be appreciated that this configuration
may facilitate inter-fitting midsole component 204 with fluid-filled chamber component
700 in the forefoot region of sole structure 200 and article of footwear 100 (see,
e.g., FIG. 2). This configuration also may enable midsole component 204 to form a
portion of a peripheral side surface of sole structure 200 at side openings of plurality
of channels 720 (see, e.g., FIGS. 2 and 3).
[0077] Similar to the construction of fluid-filled chamber component 400, in some embodiments
plurality of lobes 720 of fluid-filled chamber component 700 may include one or more
exposed distal end walls. For example, as shown in FIGS. 7 to 9, in some embodiments
fluid-filled chamber component 700 may include respective exposed distal end walls
730 (731, 732, 733, 734, 735, 736). Each exposed distal end wall may include a protruding
portion, with a furthest protruding portion or facet edge. For example, as shown in
FIGS. 7 to 9, in some embodiments lobe 725 may include a first surface portion or
facet 755 and a second surface portion or facet 756 that forms a furthest protruding
portion or facet edge 757. As shown in FIG. 9, in some embodiments fluid-filled chamber
component 700 may be formed by a first sheet of mold material that defines top surface
710, including second surface portion 756, a second sheet of mold material that defines
bottom surface 712, including first surface portion 755, and a generally trapezoidal
shaped parting line between molded top surface 710 and bottom surface 712 that defines
a furthest protruding portion or facet edge 757 between first surface portion or facet
755 and second surface portion or facet 756. Similar to fluid-filled chamber component
400, the parting line between the first sheet of mold material forming the top surface
710 and the second sheet of mold material forming the bottom surface 712 may follow
a line of trapezoidal-shaped furthest protruding portions (e.g., protruding portion
or facet 757) around a perimeter of fluid-filled chamber component 700. Similar to
fluid-filled chamber component 400, in some embodiments a height H2 (912) of furthest
protruding portion or edge portion 757 may be selected to be greater than 50% of a
height H1 (910) of lobe 725, as shown in FIG. 9.
[0078] Those skilled in the art readily will appreciate other similarities and differences
in construction and/or configuration of fluid-filled chamber components 400 and 700
selective to the heel region and the forefoot region of sole structure 200 and article
of footwear 100, consistent with this disclosure.
Midsole Component Features
[0079] FIG. 10 illustrates an embodiment of midsole component 1000. In some embodiments,
midsole component 1000 may correspond to midsole component 204 in FIG. 2. Accordingly,
corresponding elements of midsole component 1000 may be indicated with corresponding
reference numbers from midsole component 204 in FIG. 2 to explain certain features
of midsole component 1000.
[0080] Similar to midsole component 204, midsole component 1000 generally has a top or upper
surface 241, a bottom or lower surface 243, and a plurality of projections 240, 242,
244, 246 that extend downward at the lower surface of midsole component 1000. Midsole
component 1000 may be formed of a foam material, such as a polyurethane foam material.
The upper surface may have a smooth finish that is configured to follow contours of
a foot and provide a comfortable fit. Projections 240, 242, 244, 246 generally are
wider nearer to the upper surface 241 of midsole 204 than at the lower surface 243,
at distal ends of the projections.
[0081] As shown in FIG. 10, midsole component 1000 may include a plurality of projections
configured to inter-fit with one or more fluid-filled chamber components of a sole
structure, such as fluid-filled chamber component 206 (e.g., heel chamber 210 and
forefoot chamber 220) of sole structure 200 in FIG. 2. In some embodiments, midsole
component 1000 may include a first plurality of projections 240 (1021, 1022, 1023,
1024, 1025) located in the heel region, and a second plurality of projections 242
(1026, 1027, 1028, 1029) located in a forefoot region. In some embodiments, midsole
component 204 may include a projection 244 (1051) located in a midfoot region, and
a projection 246 (1055) located in a toe region.
[0082] It will be appreciated that this configuration, including plurality of projections
1021-1029, 1051, and 1055, may enable inter-fitted assembly of midsole component 1000
with heel chamber 210 and forefoot chamber 220 of fluid-filled chamber component 206
to form assembled sole structure 200 of FIG. 2. Specifically, plurality of projections
1021, 1022, 1023, 1024, and 1025 may be inter-fitted with plurality of channels 218
of heel chamber 210, e.g., with plurality of channels 441, 442, 443, 444, and 445
of fluid-filled chamber component 400 in FIGS. 4 to 6. Similarly, plurality of projections
1026, 1027, 1028, and 1029 may be inter-fitted with plurality of channels 228 of forefoot
chamber 220, e.g., with plurality of channels 741, 742, 743, and 744 of fluid-filled
chamber component 700 in FIGS. 7 to 9. Similarly, projection 1051 further may be inter-fitted
with channel 446 of fluid-filled chamber component 400 of FIGS. 4 to 6 and channel
752 of fluid-filled chamber component 700 in FIGS. 7 to 9, and projection 1055 may
be inter-fitted with channel 753 of fluid-filled chamber component 700 in FIGS. 7
to 9.
[0083] Plurality of projections 1021-1029, 1051, and 1055 have configurations that inter-fit
with configurations of plurality of channels of fluid-filled chamber component 206.
As shown in FIG. 10, each of plurality of projections 1021-1029 may have a generally
truncated conical configuration that extends in a direction from upper surface 241
to lower surface 243 of midsole component 1000. It will be appreciated that, because
plurality of projections 1021-1029 are inter-fitting with plurality of channels 218
and 228 of heel chamber 210 and forefoot chamber 220 of fluid-filled chamber component
206, this generally truncated conical configuration also extends from a direction
of a top surface to a bottom surface of heel chamber 210 and forefoot chamber 220
of fluid-filled chamber component 206. Projections 1051 and 1055 similarly may have
generally truncated conical or other geometric configurations that extend from a top
surface to a bottom surface of midsole component 1000.
[0084] As shown in FIGS. 2 and 10, in some embodiments, plurality of projections 1021, 1022,
1023, 1024 may be truncated at the lower surface of midsole 1000 to form a flat or
planar surface suitable for securing the lower surface of midsole component 1000 to
an upper surface of outer sole component 208 of sole structure 200, as shown in FIGS.
2 and 3, e.g., by adhesive or thermal bonding. Similarly, projection 1051 may be truncated
at the lower surface of midsole component 1000 to form a flat or planar surface suitable
for securing the lower surface of midsole component 1000 to the upper surface of outer
sole component 208 of sole structure 200, as shown in FIGS. 2 and 3. Similarly, projection
1055 may be truncated at a lower surface of midsole component 1000 to form a flat
or planar surface suitable securing the lower surface of midsole component 1000 to
outer sole component 208 of sole structure 200, as shown in FIGS. 2 and 3.
[0085] In some embodiments, as shown in FIG. 10, plurality of projections 1021-1029 may
have a generally conical configuration with a generally truncated oval cross-section
(see also FIG. 2). For example, each of plurality of projections 1021-1029 may be
truncated at a medial or lateral edge of midsole component 204 to form respective
exposed side walls 1031-1039. Because plurality of projections 1021-1029 may be configured
to be inter-fitted with plurality of channels 218 and 228 of heel chamber 210 and
forefoot chamber 220 of fluid-filled chamber component 206, in some embodiments exposed
side walls 1031-1039 may be configured to correspond with side openings of plurality
of channels 218 and 228, e.g., with side openings of plurality of channels 440 (441-445)
of fluid-filled chamber component 400 in FIGS. 4-6 and side openings of plurality
of channels 740 (741-744) of fluid-filled chamber component 700 in FIGS. 7 to 9, to
form a portion of a peripheral side surface of sole structure 200. Similarly, projection
1051 may be truncated at medial and lateral sides of midsole component 204 to form
exposed side walls 1052 and 1054. In some embodiments, exposed side walls 1052 and
1054 of projection 1051 may be configured to correspond with side openings of a composite
channel formed between heel chamber 210 and forefoot chamber 220 of fluid-filled chamber
component 206 at the midfoot region of sole structure 200, to form respective portions
of the peripheral side surface of sole structure 200. In some embodiments, exposed
side walls 1031-1039, 1052, and 1054 of plurality of projections 1021-1029 and 1051
may include respective flex structures 1041-1049 (see, e.g., flex structures 1041,
1042, 1046, and 1047 shown in FIG. 10) corresponding to flex structures 247 in FIGS.
2 and 3). In some embodiments, flex structures 1041-1049 may be indentations formed
in respective exposed end walls 1031-1039. In some embodiments, a shape of the flex
structures may correspond with a shape of the exposed end walls. For example, in some
embodiments an indentation or pattern of grooves may have a generally triangular or
trapezoidal shape (see, e.g., FIGS. 1 3, and 10). In some embodiments, the flex structures
may include a plurality of flex grooves arranged in a pattern to form an overall shape
of the flex structure (see, e.g., the enlarged view of flex structure 247 in FIG.
3). As discussed below with respect to FIGS. 3 and 12, flex structures 1041-1049 may
help prevent bulging of midsole component 204 during bending or flexing of sole structure
200 and/or facilitate a smooth response performance characteristic of midsole component
204 and sole structure 200.
[0086] In some embodiments the plurality of protrusions of midsole component 1000 may be
configured to inter-fit with and/or cooperate with features of an outer sole component,
such as outer sole component 208 of FIG. 2. For example, as shown in FIGS. 2 and 10,
in some embodiments plurality of protrusions 1026, 1027, 1028, 1029 may be configured
to inter-fit with and cooperate with cut-out portions 235 and 237 of outer sole component
208 of FIG. 2 to facilitate localized and overall bending and flexing characteristics
of sole structure 200. Protrusions 1026-1029 may be inter-fitted with plurality of
channels 228 of forefoot chamber 220 such that protrusions 1026-1029 are aligned in
registration with cut-out portions 235 of outer sole component 208. It will be appreciated
that cut-out portions 235 thus expose protrusions 1026-1029 at the lower surface of
outer sole component 208 and sole structure 200. In some embodiments, protrusions
1026-1029 may be provided with flex structures, such as flex grooves or sipes 1061,
1062, 1063, and 1064, formed in the lower surface of midsole component 204 and located
at respective distal ends of plurality of projections 1026-1029. It will be appreciated
that these flex grooves may cooperate with cut-out portions 235 of outer sole component
208 to provide localized and overall bending and flexing of midsole component 204
and sole structure 200, whereby the flex grooves are exposed at the outer sole component
208 by the cut-out portions 235. In particular, this configuration may facilitate
a smooth response performance characteristic in midsole component 204 and sole structure
200.
[0087] Similarly, protrusion 1055 may be inter-fitted with forefoot chamber 220, e.g., with
channel 753 of fluid-filled chamber component 700, such that a distal end of protrusion
1055 is aligned in registration with cut-out portion 237 of outer sole component 208
of FIG. 2. It will be appreciated that cut-out portion 237 thus exposes the distal
end of protrusion 1055 at the lower surface of outer sole component 208 and sole structure
200. In some embodiments, the distal end of protrusion 1055 may be provided with a
flex structure, such as flex grooves or sipes 249 (1065), formed in the lower surface
of midsole component 204 and located at the distal end of projection 1055 adjacent
the forefoot region. It will be appreciated that flex grooves 1065 may cooperate with
cut-out portion 237 of outer sole component 208 to provide localized and overall bending
and flexing of midsole component 204 and sole structure 200. Thus, this configuration
may facilitate a smooth response performance characteristic in midsole component 204
and sole structure 200.
Outer Sole Component And Sole Structure Features
[0088] FIG. 11 illustrates in bottom plan view an embodiment of sole structure 1100. In
some embodiments, sole structure 1100 may correspond to sole structure 200 of FIG.
2. Accordingly, elements of sole structure 1100 may be indicated with corresponding
reference numbers from sole structure 200 in FIG. 2 to describe certain features of
sole structure 1100.
[0089] As shown in FIG. 11, in some embodiments sole structure 1100 may include inter-fitted
midsole structure 204, fluid-filled chamber component 206, and an outer sole 208.
[0090] As discussed above with reference to FIG. 2, in some embodiments outer sole component
208 may include one or more outer sole components or elements. As shown in FIG. 11,
in some embodiments outer sole component 208 may include a first outer sole component
or element 230 located in heel region 110 of sole structure 200, a second outer sole
component or element 232 generally located in heel region 110 and midfoot region 112
of sole structure 200, a third outer sole component or element 234 generally located
in midfoot region 112 and forefoot region 114 of sole structure 200, and a fourth
outer sole component or element 236 generally located in toe region 116 of sole structure
200. As shown in FIG. 11, in some embodiments outer sole component or element 230
and outer sole component or element 232 may be connected at flex groove 231, with
outer sole component or element 230 being generally disposed in a heel strike area
of heel region 230. In some embodiments, outer sole component or element 232 and outer
sole component or element 234 may be connected at flex groove 233.
[0091] Outer sole component 208 generally may be disposed below midsole component 204 and
fluid-filled chamber component 206, and may be formed of an abrasion resistant material
suitable for contact with a ground surface. For example, outer sole component 208
may be disposed below midsole component 204 and fluid-filled chamber component 206
in heel region 110 to protect these components from abrasive contact with a ground
surface in heel region 110, e.g., during a heel strike of a running stride. Similarly,
outer sole component 208 may be disposed below midsole component 204 and/or fluid-filled
chamber component 206 in forefoot region 114, e.g., below the metatarsals or balls
of the foot, to protect these components from abrasive contact with a ground surface,
e.g., during a pivot motion. It will be appreciated that, as generally shown in FIG.
11, in bottom plan view outer sole component element 234, including cut-out portions
235 and 237, generally may have a configuration, including size and shape, substantially
consistent with a size and shape of forefoot chamber 220 (700).
[0092] As shown in FIG. 11, in some embodiments outer sole component 208 may include one
or more outer flex structures that cooperate with one or more flex structures of inter-fitted
midsole component 204 and/or fluid-filled chamber component 206 to facilitate localized
compression, bending, and flexing of sole structure 200. For example, as shown in
FIG. 11, outer sole component 208 may include groove portions 231, 233 in heel region
110 and midfoot region 112, respectively, to facilitate localized bending or flexing
of sole structure 200 in heel region 110 and midfoot region 112. Similarly, in some
embodiments outer sole component 208 may include cut-out portions 235, 237 located
in forefoot region 114, to facilitate localized bending or flexing of sole structure
200 in forefoot region 114. As shown in FIGS. 11, in some embodiments two pairs of
cut-out portions 235 may be provided on opposing medial and lateral sides of outer
sole 208, with a connecting portion of outer sole 208 disposed between the cut-out
portions. In some embodiments, a cut-out portion 237 may be provided extending from
a medial to lateral side of outer sole 208, thereby defining outer sole component
208 as two separate outer sole component elements. In some embodiments, outer sole
208 may include one or more traction elements 239 for providing traction with a ground
surface or other external surface (e.g., a soccer ball). For example, as shown in
FIGS. 2 and 11, in some embodiments a first outer sole portion (heel portion) 230
may include a plurality of recessed traction elements (e.g., indentations or wells)
1110, and each of a second outer sole portion (midfoot portion) 232, a third outer
sole portion (forefoot portion) 234, and a fourth outer sole portion (toe portion)
236 may include a plurality of raised traction elements (e.g., protruding cleats)
1112.
[0093] As shown in FIG. 11, in some embodiments, outer sole component 208 may be provided
with flex grooves 233 located in the midfoot region of sole structure 1100 (200) and
aligned with inter-fitted structures of midsole component 204 and fluid-filled chamber
component 206, e.g., generally conforming to a contour of inter-fitted channel 752
of forefoot chamber 700 (220) and protrusion 244 (1051) of midsole component 204.
In some embodiments this configuration may align terminal ends of flex grooves 233
in registration with flex structures 247(1048, 1148) of exposed side walls 244 (1052
and 1054) of midsole component 204. It will be appreciated that this configuration
may provide improved flexibility, smooth response, and other performance characteristics
at the midfoot region of sole structure 200.
[0094] Plurality of projections 240, 242, 244, and 246 on lower surface 243 of midsole component
204 may be disposed at selected locations around the heel region, midfoot region,
and forefoot region of midsole component 204, such that respective exposed side walls
248 (1031-1039, 1052, and 1054) collectively form a portion of a peripheral side surface
of sole structure 1100 (200).
[0095] In some embodiments, as shown in FIG. 11, projecting portions of respective exposed
distal end walls 217 and 227 of heel chamber 210 and forefoot chamber 220 (e.g., exposed
distal end walls 431-436 of fluid-filled chamber component 400 and exposed distal
end walls 731 to 736 of fluid-filled chamber component 700) may extend or project
outward further than the portion of the peripheral side surface formed by adjacent
exposed side walls 248 of sole structure 1100 (200). In some embodiments a portion
of a peripheral side surface of sole structure 1100 (200) formed by exposed side walls
248 of midsole component 204 may be generally vertical (see, e.g., the forefoot region
of sole structure 1100 (200)). It will be appreciated that, however, that in some
embodiments, a portion of a peripheral side surface of sole structure 1100 (200) formed
by exposed side walls 248 may be inclined inward or outward relative to vertical (see,
e.g., midfoot and heel regions of sole structure 1100 (200)). As shown in FIG. 11,
in some embodiments exposed distal end portions 217 (430) and 227 (730) of heel chamber
210 (400) and forefoot chamber 220 (700), respectively, alternate with exposed side
walls 248 (1031-1039, 1052, 1054) of midsole component 204 along a length of the sole
structure 1100 (200). In some embodiments, flex grooves 247 also are visible from
the sides and bottom of sole structure 1100 (200).
[0096] As shown in FIG. 11, in some embodiments plurality of cut-out portions 235 (1161-1164)
align in registration with flex structures 249 (1061-1064) on midsole component 204,
respectively, such that flex structures 249 (1061-1064) are exposed and visible through
plurality of cut-out portions 235 (1161-1164). It will be appreciated that this configuration
may facilitate localized and overall bending and flexing of sole component 1100 (200),
and provide a desired smooth response characteristic and/or other performance characteristics
of sole structure 1100 (200) and article of footwear 100.
Smooth Response Performance Features
[0097] Features of a smooth response performance will now be described with respect to an
embodiment of an assembled sole structure 200 as shown in FIG. 3 and 12. FIG. 12 is
a side profile view of the assembled sole structure 200 of FIG. 3 that is bent or
flexed at a location between the forefoot region and the midfoot region of sole structure
200. FIGS. 3 and 12 illustrate in enlarged view a portion of sole structure 200 at
a location of bending or flexing. As shown in FIG. 12, a toe portion and forefoot
region of sole structure 200 is in contact with a ground surface and the sole structure
200 is bent or flexed so that a heel region and midfoot region of sole structure 200
is elevated from the ground surface at an angle [beta] (1210).
[0098] As shown in the enlarged views in FIGS. 3 and 12, in some embodiments a projection
242 (1062) of midsole component 204 (1000) may have a generally trapezoidal configuration
(pointing generally down) forming an exposed side wall 248 (1037) with a flex structure
247 (1047) having a corresponding generally trapezoidal (or triangular) shape. Exposed
side wall 248 (1037) is located between two adjacent lobes 226 (734, 735) of a forefoot
chamber 220 (700) of fluid-filled chamber component 206, where each of the two adjacent
lobes 226 (724, 725) has a generally trapezoidal shape (pointing generally up). As
shown in FIGS. 3 and 12, in some embodiments projection 242 (1062) may have an exposed
distal end wall including a flex structure 249 (1062), such as a flex groove or sipe,
that may be exposed through a cut-out portion 235 of outer sole component 208. As
shown in FIGS. 3 and 12, flex groove or sipe 249 (1062) may be defined by side surfaces
314 that extend up through a lower portion of flex structure 247 (1047) formed in
the exposed side wall 248 (1037), and may have a tapered lower surface 315 that terminates
at a side surface 312 of cut-out portion 235 of outer sole component 208.
[0099] When sole structure 200 is bent or flexed at flex structure 249 (1062), projection
242 (1027) may be compressed between adjacent lobes 226 (724, 725) of forefoot chamber
220 (700), as illustrated by dashed lines around a periphery of flex structure 247
(1047) in FIG. 12. It will be appreciated that, because projection 242 (1027) has
a generally trapezoidal (or triangular) cross-section, and because midsole component
204 (1000) may be made of a foam material, a portion of midsole component 204 (1000)
located adjacent the top surface 222 (710) of forefoot chamber 220 (700) between adjacent
lobes 226 (724, 725) may be compressed to a greater extent (i.e., a greater distance)
than a portion of midsole component 204 (1000) located adjacent the bottom surface
224 (712) of forefoot chamber 220 (700). It also will be appreciated that flex groove
or sipe 249 (1062) may enable midsole component 204 (1000) to flex to a more open
configuration. It further will be appreciated that cut-out portion 235 may provide
both outer flex structure that facilitates bending and flexing of midsole component
204 and reinforcing structure that helps prevent over stretching of flex groove or
sipe 249 (1062) that may cause damage, such as tearing, of midsole component 204 at
flex groove or sipe 249. It further will be appreciated that an indented configuration
of flex structure 247 (1047) may enable midsole component 204 to flex at projection
242 (1027) without buckling and/or bulging in a direction laterally outwards at protrusion
242 (1027). Thus, in some embodiments this configuration may provide a smooth response
performance characteristic for sole structure 200 and article of footwear 100.
[0100] Benefits explained herein with respect to different elements of sole structures 103,
200, and 1100 may be provided by the elements individually, and further may be increased
even more so by combining certain of the elements together.
[0101] According to one aspect, the present disclosure provides an element of a sole structure
for an article of footwear. The element of the sole structure includes a fluid-filled
chamber component having a central portion, a plurality of lobes extending outward
from the central portion, and a plurality of channels formed between the plurality
of lobes. The plurality of channels extend in a direction from a top surface of the
fluid-filled chamber component to a bottom surface of the fluid-filled chamber component.
At least a first channel of the plurality of channels is defined by two adjacent lobes
of the plurality of lobes, forming a side opening of the first channel located opposite
the central portion of the fluid-filled chamber component. The side opening of the
first channel corresponds to a portion of a peripheral side of the sole structure.
At least a first lobe of the two adjacent lobes forms the side opening of the first
channel and has an exposed distal end wall that forms a portion of a peripheral side
surface of the sole structure. The exposed distal end wall has a first facet edge
that extends further outward from the central portion than the portion of the peripheral
side of the sole structure associated with the side opening of the first channel.
[0102] In some configurations, the exposed distal end wall includes an exposed first facet
arranged at an angle relative to the peripheral side of the sole structure associated
with the side opening of the first channel, such that one portion of the exposed first
facet extends further outward from the central portion of the fluid-filled chamber
component than other portions of the exposed first facet.
[0103] In some configurations, an upper portion of the exposed first facet extends further
outward than a lower portion of the exposed first facet.
[0104] In some configurations, the exposed distal end wall includes a second facet that
is angled relative to the first facet and defines a furthest protruding facet edge
of the exposed distal end wall at an interface of the first facet and the second facet.
[0105] In some configurations, the furthest protruding facet edge includes a generally trapezoidal
arched shape.
[0106] In some configurations, at least the first lobe has a cross-section that is generally
trapezoidal.
[0107] In some configurations, at least the two adjacent lobes each has a cross-section
that is generally trapezoidal.
[0108] In some configurations, a size of a cross-section of at least the first lobe generally
increases in a direction away from the central portion of the fluid-filled chamber
component.
[0109] In some configurations, at least the first channel has a generally truncated conical
configuration.
[0110] In some configurations, at least the first channel has a generally trapezoidal cross-section.
[0111] In some configurations, the facet edge is located closer to a top surface than a
bottom surface of the fluid-filled chamber component.
[0112] In some configurations, the peripheral side of the sole structure associated with
the side opening of the first channel is generally vertical relative to a bottom surface
of the sole structure.
[0113] According to another aspect, the present disclosure provides a sole structure for
an article of footwear. The sole structure includes a fluid-filled chamber component
and a midsole component. The fluid-filled chamber component includes a central portion,
a plurality of lobes extending outward from the central portion, and a plurality of
channels formed between the plurality of lobes. Each of the plurality of channels
extends in a direction from a top surface of the fluid-filled chamber component to
a bottom surface of the fluid-filled chamber component. The midsole component is inter-fitted
with the plurality of lobes of the fluid-filled chamber and includes a plurality of
projections. Each of the plurality of projections extends through the plurality of
channels of the fluid-filled chamber component. The midsole component forms a portion
of a peripheral side surface of the sole structure. At least a first lobe of the plurality
of lobes has an exposed distal end wall including a projecting portion that extends
further outward from the central portion of the fluid-filled chamber component than
the portion of the peripheral side surface of the sole structure formed by the midsole
component.
[0114] In some configurations, the midsole component has an upper surface, a lower surface,
and a plurality of projections that extend through and are inter-fitted with the plurality
of channels of the fluid-filled chamber component in a direction from the top surface
of the fluid-filled chamber component to the bottom surface of the fluid-filled chamber
component.
[0115] In some configurations, exposed side walls of the plurality of projections form the
portion of the peripheral side surface of the sole structure.
[0116] In some configurations, at least one exposed side wall of the plurality of projections
includes a flex structure.
[0117] In some configurations, the flex structure has a wedge-shaped configuration that
tapers in a direction from the top surface of the fluid-filled chamber component to
the bottom surface of the fluid-filled chamber component.
[0118] In some configurations, the flex structure includes at least one groove formed in
the at least one exposed side wall.
[0119] In some configurations, the flex structure includes a plurality of parallel grooves
formed in the at least one exposed side wall.
[0120] In some configurations, the midsole component includes a flex structure associated
with the lower surface of the midsole component at a distal end of at least one projection
of the plurality of projections.
[0121] In some configurations, the flex structure includes at least one groove formed in
the lower surface of the midsole component at a distal end of the at least one projection.
[0122] In some configurations, the exposed side walls of the plurality of projections extend
in a generally vertical direction relative to a bottom surface of the sole structure.
[0123] In some configurations, the exposed side walls of the plurality of projections are
inclined in a vertical direction relative to a bottom surface of the sole structure.
[0124] In some configurations, at least some of the exposed distal end walls of the plurality
of lobes of the fluid-filled chamber component and at least some of the exposed side
walls of the plurality of projections of the midsole component alternate in an inter-fitted
configuration to form the peripheral side surface of the sole structure.
[0125] In some configurations, at least one of the exposed distal end walls of the plurality
of lobes of the fluid-filled chamber and the exposed side walls of the plurality of
projections of the midsole component have generally trapezoidal shapes.
[0126] In some configurations, at least one of the exposed distal end walls of the plurality
of lobes of the fluid-filled chamber and the exposed side walls of the plurality of
projections of the midsole component have generally triangular shapes.
[0127] In some configurations, the inter-fitted configuration of the exposed distal end
walls of the fluid-filled chamber component and the exposed side walls of the plurality
of projections presents a generally zigzag surface configuration in the peripheral
side surface of the sole structure.
[0128] In some configurations, the sole structure includes an outer sole component having
an exposed surface configured to engage a ground surface and a non-exposed surface
opposite the exposed surface.
[0129] In some configurations, a top surface of the fluid-filled chamber component engages
a first portion of the lower surface of the midsole component, a bottom surface of
the fluid-filled chamber component engages a first portion of the non-exposed surface
of the outer sole component, and a first portion of the lower surface of the midsole
component engages a second portion of the non-exposed surface of the outer sole component.
[0130] In some configurations, the exposed surface of the outer sole component comprises
a flex structure associated with at least one projection of the plurality of projections
of the midsole component.
[0131] In some configurations, the exposed surface of the outer sole component comprises
at least one flex groove associated with at least one projection of the plurality
of projections of the midsole component.
[0132] In some configurations, the midsole component comprises at least one flex structure
associated with the lower surface of the midsole component at a distal end of at least
one projection of the plurality of projections of the midsole component.
[0133] In some configurations, the outer sole component comprises at least one outer flex
structure that is aligned in registration with the at least one flex structure of
the midsole component.
[0134] In some configurations, the outer flex structure of the outer sole component comprises
at least one flex groove in the exposed surface of the outsole component that is aligned
in registration with the at least one flex structure of the midsole component.
[0135] In some configurations, the outer flex structure of the outer sole component comprises
at least one cut-out portion that is aligned in registration with the at least one
flex structure of the midsole component and exposes the at least one flex structure
of the midsole component.
[0136] According to another aspect, the present disclosure provides an article of footwear.
The article of footwear includes an upper and a sole structure. The sole structure
is associated with the upper and includes at least one fluid-filled chamber component
and a midsole component. The at least one fluid-filled chamber component includes
a central portion, a plurality of lobes extending outward from the central portion,
and a plurality of channels formed between the plurality of lobes. The plurality of
channels extend in a direction from a top surface of the fluid-filled chamber component
to a bottom surface of the fluid-filled chamber component. The midsole component is
inter-fitted with the plurality of lobes and the plurality of channels of the fluid-filled
chamber component. The midsole component forms a portion of a peripheral side surface
of the sole structure. At least one of the plurality of lobes has an exposed distal
end wall including a projecting portion that extends further outward from the central
portion of the fluid-filled chamber component than the portion of the peripheral side
surface of the sole structure formed by the midsole component.
[0137] In some configurations, the midsole component has an upper surface, a lower surface,
and a plurality of projections that extend through and are inter-fitted with the plurality
of channels of the fluid-filled chamber component in a direction from the top surface
of the of the fluid-filled chamber component to the bottom surface of the fluid-filled
chamber component.
[0138] In some configurations, exposed side walls of the plurality of projections form the
portion of the peripheral side surface of the sole structure.
[0139] In some configurations, the sole structure further includes an outer sole component
disposed between a ground surface and the at least one fluid-filled chamber component
and the midsole component.
[0140] In some configurations, the sole structure further includes an outer sole component
disposed between a ground surface and the at least one fluid-filled chamber component
and the midsole component.
[0141] In some configurations, the outer sole component has an exposed surface configured
to engage the ground surface and a non-exposed surface opposite the exposed surface.
[0142] In some configurations, the top surface of the fluid-filled chamber component engages
a first portion of the lower surface of the midsole component, the bottom surface
of the fluid-filled chamber component engages a first portion of the non-exposed surface
of the outer sole component, and a first portion of the lower surface of the midsole
component engages a second portion of the non-exposed surface of the outer sole component.
[0143] According to yet another aspect, the present disclosure provides a method of making
an element of a sole structure for an article of footwear. The method includes shaping
a first sheet of mold material to form a top surface of a chamber component. The method
also includes shaping a second sheet of mold material to form a bottom surface of
the chamber component. The method further includes joining the first sheet of molding
material and the second sheet of molding material at a parting line of the chamber
component to form a sealed fluid-filled chamber component having a central portion,
a plurality of lobes extending outward from the central portion, and a plurality of
channels formed between the plurality of lobes. In some configurations, the plurality
of channels extend in a direction from the top surface of the fluid-filled chamber
component to the bottom surface of the fluid-filled chamber component. In some configurations,
at least a first channel of the plurality of channels is defined by two adjacent lobes
of the plurality of lobes forming a side opening of the first channel located opposite
the central portion of the fluid-filled chamber component. In some configurations,
the side opening of the first channel corresponds to a portion of a peripheral side
of the sole structure. In some configurations, at least a first lobe of the two adjacent
lobes forms the side opening of the first channel having an exposed distal end wall
configured to form a portion of a peripheral side surface of the sole structure. In
some configurations, the parting line forms a projecting portion of the exposed distal
end wall that extends further outward from the central portion than the portion of
the peripheral side of the sole structure associated with the side opening of the
first channel.
[0144] In some configurations, joining the first sheet of mold material and the second sheet
of mold material includes one of a bonding process and a co-molding process.
[0145] According to the invention, shaping the first sheet of mold material includes forming
a first facet of the exposed distal end wall, shaping the second sheet of mold material
includes forming a second facet of the exposed distal end wall, and joining the first
sheet of mold material and the second sheet of mold material includes forming a facet
edge between the first facet and the second facet at the parting line.
[0146] In some configurations, joining the first sheet of mold material and the second sheet
of mold material includes forming a trapezoidal shaped facet edge between the first
facet and the second facet at the parting line.